Method for removing floating yarn ends from a pile fabric



Nov. 14, 1967 v A. SCHUSTER 3,351,990

METHOD FOR REMOVING FLOATING YARN ENDS FROM A FILE FABRIC Filed July 30, 1964 2 Sheets-Sheet 'I.

4 INVENTOR Nov. 14, 1967 SCHUSTER 3,351,990

, METHOD FOR REMOVING FLOATING YARN ENDS FROM A FILE FABRIC Filed July 50, 1964 2 Sheets-Sheet 2 lNVENTOR m: dad/"6 a ATTORNEY United States Patent Ofilice Patented Nov. 14, 1967 METHQD FOR REMOVING FLOATING YARN ENDS FRUM A PILE FABRIC Alfred Schuster, Mayer], Rhineland, Germany, assignor to Union-Teppich-Fabrik Walter Poser & Co. KG., Mayan, Rhineland, Germany Filed July 30, 1964, Ser. No. 386,145

Claims priority, application Germany, Aug. 1, 1963,

4 Claims. (Cl. 2615) The present invention relates to a method and apparatus for removing floating pile yarn ends from a pile fabric, such as a multi-colored carpet weave.

Carpet weaves are known which have multi-colored pile yarns located between the top ply and the bottom ply of the fabric, and forming tufts projecting from a top surface after the fabric has been split between the two plies. The pile warp yarns, which do not participate in the production of the pattern, and which are usually referred to as stuffers or dead warps, float between the tufts in the top ply, and the bottom ply and are cut with the same when the fabric is split between the two plies.

The floating portions of the pile warp yarns must be removed after the weaving and splitting of the pile fabric, and this is frequently done manually by means of a scraper. This operation is tiresome and time consuming and increases the cost of the fabric. Furthermore, the scraping and clearing operation affects the tufts, because repeated passage of the scraper over the same part of the pile cannot be avoided, so that the tight twist of the tufts is loosened. As a result, a frayed appearance is imparted to the pile, and its colors are detrimentally affected. Moreover, the manual operation causes displacement of individual tufts out of the pattern position, so that the contours of the colored pattern are blurred.

It is also known to remove the dead pile yarn ends by rotating drums covered with a card clothing by moving the carpet in the direction of the warp over the card clothing. This method subjects the tufts to even greater mechanical wear and tear than the manual operation, since the dense card clothing pulls numerous fibers out of the tufts of the pile. Nevertheless, a complete removal of the dead pile yarn ends cannot be achieved in this manner. Floating pile yarns remaining in the fabric gradually work their way to the surface of a carpet when the same is used, so that the appearance of the carpet is detrimentally affected which leads to complaints by the customers.

Irrespective of whether the pile yarn ends are pulled out of the fabric by manual or machine operation, it is necessary to cut off the free ends of these pile yarns which project beyond the surface of the pile. The other ends of the pile yarns remain attached to the fabric and form the tufts. The cutting off of the loose ends of the pile yarns is done with a shearing machine which operationally follows the card-clothed drums in the production line. Shearing of the relatively long loose yarn ends subjects the cutting tools to such a wear that they soon become blunt requiring sharpening or grinding after a short period of use which results in an interruption of the continuous production.

It is one object of the invention to overcome the disadvantages of known methods for removing the dead pile yarn ends of a pile fabric, and to remove the dead pile yarn ends in such a manner that the operation does not impair the quality and appearance ofthe fabric.

Another object of the invention is to provide an apparatus by which the dead pile yarn ends of a pile fabric are efficiently raised above the top surface of the pile and cut off.

Another object of the invention is to provide a method and apparatus for removing dead pile yarn ends in a continuous and inexpensive operation from a pile fabric, such as a carpet.

Another object of the invention is to provide means for individually raising dead pile yarn ends above the top surface of the fabric so that the raised ends can be easily and efiiciently removed.

With these objects in view, the present invention relates to a method of removing floating yarn ends. The method comprises the steps of placing a pointed tool, such as a spike, in a position projecting in a plane extending in the weft direction of the fabric transversely to the fabric through the tufts into the proximity of the bottom of the fabric; moving the fabric and the tool relative to each other in the weft direction, and preferably also in the warp direction of the fabric so that the free ends of the floating yarns are raised above the top surface of the pile of the fabric; and cutting off or otherwise removing the raised yarn ends.

In a preferred method of the invention, the fabric is attached to a rotating cylinder with the weft extending in circumferential direction of the cylinder, so that the rotating cylinder moves the fabric in the weft direction. The pointed tool, or spike, is simultaneously moved in the warp direction of the fabric so that the free ends of the floating yarns are successively raised above the top surface of the pile where they are cut off.

An apparatus according to the invention includes first support means, preferably having a cylindrical surface for supporting the fabric; second support means for supporting a pointed tool projecting through the tufts of the fabric; and cutting means disposed following the pointed tool in the direction of relative movement between the first and second support means in the weft direction. In the preferred embodiment of the invention, the pointed tool is movable in the warp direction so that the entire area of the fabric is cleared of floating pile yarn ends in a continuous operation.

Due to the fact that in accordance with the invention, individual pile yarn ends are raised above the surface of the pile and individually cut off, the structure and shape of the tufts is not detrimentally affected, and a complete removal of all floating pile yarn ends is reliably assured.

Furthermore, the cutting blades are not subjected to any embodiments when read in connection with the accompanying drawings, in which:

FIG. 1 is a fragmentary cross sectional view illustrating one embodiment of the invention; and

FIG. 2 is a front elevation, partially in axial section, of the embodiment of FIG. 1; and

FIG. 3 is a longitudinal sectional view taken in the warp direction of a two-ply fabric.

Referring now to the drawings, a woven pile fabric 2 is placed on the cylindrical surface of a rotary support 1 so that the weft-yarns extend in circumferential direction,

and the warp yarns extend in axial direction and the tufts project outward from the fabric in radial direction. Consequently, support drum 1 has an axial length at least equal to the length of the pile fabric, and a circumferential extension greater than the width of the fabric. The bottom ply of the pile fabric lies on the cylindrical surface of the support drum 1, and the pile faces outward. The dead pile yarn ends are also warp yarns, and extend in axial direction of the support drum 1.

This will be best understood with reference to FIG. 3. A first ply A and a second ply B are woven on a loom and after the weaving has been completed, the two ply fabric is cut along the line C so that the fabric is split into two halves, each of which has a base and tufts projecting from the base. Each ply comprises base yarn D, crossing warp yarns E, transverse weft yarns F, and differently colored pile yarns G G G The pile yarns G G G are interlaced into the upper base fabric U and into the lower base fabric L, and then float for a considerable distance until again interlaced into the upper and lower base fabrics.

When the two ply fabric is out along the plane C, two pile fabrics result, each of which has a base and a pile. However, the free ends of cut floating yarns are still located between the proper tufts formed by cutting the yarns forming each pair of opposite tufts.

In accordance with the present invention, each of the two pile fabrics is treated for the purpose of first raising the portions G G 6;, of the pile yarns to a position projecting above the top surface of the tufts, as shown at 24 .in FIG. 1. The tufts formed by cutting along the plane C have the proper length and form the pile surface, but the floating yarn portions, which extend partly in the warp direction, must be raised to a position parallel to the other portions of the pile yarns forming the tufts, and in this position, they project beyond the top surface of the pile as shown at 24 in FIG. 1. Thereupon, the projecting ends 24 are cut off by the cutter 5.

As clearly shown in FIGS. 1 and 2, a pointed tool 3 projects through the pile tufts to the base fabric 23. FIGS. 1 and 2 show only one base fabric 23 and a pile 21, and do not show the other base fabric and the pile of the same, since the double ply carpet weave is split before performing the operations according to the present invention, so that the operations are carried out only with one-half of the double ply carpet weave shown in FIG. 3.

The selvedges 22 of the base 23 of the fabric are woven somewhat wider than is usual, and attached by a suitable holding means, such as pin boards 12 to the walls of a recess in the drum surface.

A shaft 13 is mounted in bearings 14, and is driven by a motor, not shown, to rotate support drum 1 in the direction of the arrow a.

The pointed tool, shown to be a spike 3, is mounted on a support 4 which is movable in axial direction of support drum 1 in the direction of the arrow b, and along a bed 41 corresponding to the tool support of a lathe. The pointed spike 3 is adjusted in radial direction of the support drum 1 so that .its point projects through the tufts into the proximity of the inner bottom ply 23 of the fabric as shown in FIGS. 1 and 2, and thus engages the loose pile yarn ends which are located between the tufts of the fabric. The pointed tool 3 extends at an acute angle to the surface of the support drum 1 and to the surface of the fabric so that the loose pile yarn ends slide upon the pointed tool and are raised above the top surface of the pile, assuming a radially projecting position 24.

The rate of feed of support 4 and tool 3 across the rotating fabric 2 in axial direction of the drum is exactly determined so that the tool will consecutively engage and raise the loose ends of the floating pile yarns according to the rate of feed of tool 3 in axial direction of support drum 1 and in the warp direction of the fabric. The tool 3 is located in a plane extending in the weft direction of the fabric, and perpendicularly to the axis of the drum.

A cutting means in the form of a rotary shearing cylinder 5 of selected axial width is located substantially in the same plane and follows tool 3 in the direction of rotation of support drum 1. Shearing cylinder 5 is moved parallel to the axis of drum 1 in the direction of the arrow b at the same speed as support 4 and tool 3. Consequently, relatively short lengths of pile yarn ends are lifted out of the pile during each rotation of support drum -1, and are cut off during the same rotation by cutting means 5.

It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of methods for removing loose yarn ends from a fabric differing from the types described above.

While the invention has been illustrated and described as embodied in an apparatus and method for removing floating pile yarn ends from the tufts of a split two-ply pile fabric, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.

Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.

What is claimed as new and desired to be secured by Letters Patent is:

1. The method of removing floating yarn ends located between the tufts of a pile fabric of predetermined dimensions, comprising the steps of engaging the free ends of floating yarns with a pointed tool projecting through the tufts into the proximity of the base of the pile fabric; causing relative rotary movement of said pile fabric and said tool repeatedly substantially in the weft direction of said pile fabric so that the free ends of floating yarns between said tufts in the path of said tool are raised by said tool above the top surface of said tufts; causing relative axial movement of said pile fabric and said tool in the direction of the axis of said relative rotary movement and in the warp direction of the pile fabric during said repeated movements in the weft direction so that the entire pile of said pile fabric is run through by said tool and all free ends of the floating yarns are raised above the top surface of the pile; and cutting off said free ends of said floating yarns at the top surface of said pile.

2. The method of claim 1 including causing movement of said pile fabric and said tool relative to each other in the warp direction during the relative movement in the weft direction.

3. The method of claim 1 and including the step of engaging said free ends with said pointed tool while the same extends in the weft direction at an acute angle to the base of said pile fabric and with its point in the proximity of the base of said pile fabric.

4. The method of removing floating yarn ends located between the tufts of a pile fabric of predetermined dimensions, comprising the steps of mounting the base of the pile fabric on a cylindrical support so that the warp yarns of the base extend in axial direction, the weft yarns extend in circumferential direction, and the tufts project radially outward; engaging the free ends of floating yarns with a pointed tool projecting through said tufts into the proximity of the top surface of the base of said pile fabric; rotating said support so that the free ends of floating yarns located between said tufts are engaged. and raised by said tool above the top surface of said tufts along a strip portion of said pile fabric; cutting by a cutter said raised free end portions at the level of the top surface of said tufts along said strip 5 portion during rotation of said support; and moving said tool and said cutter in axial direction of said support and in warp direction of said base of said pile fabric so that adjacent strip portions are successively passed by said tool and said cutter. 5

References Cited UNITED STATES PATENTS 221,932 11/1879 Moses 26-15 621,304 3/1899 Josephy 26-15 10 6 1,164,751 12/1915 Roberts 26-15 2,206,243 7/1940 Turano 2615 2,730,787 1/1956 Bechtold 2615 FOREIGN PATENTS 256 1902 Great Britain. 5,688 1828 Great Britain. 23,093 1/ 1901 Switzerland.

ROBERT R. MACKEY, Primary Examiner. 

1. THE METHOD OF REMOVING FLOATING YARN ENDS LOCATED BETWEEN THE TUFTS OF A PILE FABRIC OF PREDETERMINED DIMENSIONS, COMPRISING THE STEPS OF ENGAGING THE FREE ENDS OF FLOATING YARNS WITH A POINTED TOOL PROJECTING THROUGH THE TUFTS INTO THE PROXIMITY OF THE BASE OF THE PILE FABRIC; CAUSING RELATIVE ROTARY MOVEMENT OF SAID PILE FABRIC AND SAID TOOL REPEATEDLY SUBSTANTIALLY IN THE WEFT DIRECTION OF SAID PILE FABRIC SO THAT THE FREE ENDS OF FLOATING YARNS BETWEEN SAID TUFTS IN THE PATH OF SAID TOOL ARE RAISED BY SAID TOOL ABOVE THE TOP SURFACE OF SAID TUFTS; CAUSING RELATIVE AXIAL MOVEMENT OF SAID PILE FABRIC AND SAID TOOL IN THE DIRECTION OF THE AXIS OF SAID RELATIVE ROTARY MOVEMENT AND IN THE WARP DIRECTION OF THE PILE FABRIC DURING SAID REPEATED MOVEMENT IN THE WEFT DIRECTION SO THAT THE ENTIRE PILE OF SAID PILE FABRIC IS RUN THROUGH BY SAID TOOL AND ALL FREE ENDS OF THE FLOATING YARNS ARE RAISED ABOVE THE TOP SURFACE OF THE PILE; AND CUTTING OFF SAID FREE ENDS OF SAID FLOATING YARNS AT THE TOP SURFACE OF SAID PILE. 